Method of manufacturing dynamoelectric machines

ABSTRACT

Composite structure includes winding support with windings accommodated thereon and a housing means that does not include a metal case or shell and that does include a substantially rigid primary structural member formed of an interstitial mass of inert particulate material. Resinous material occupies interstices of interstitial mass and bonds inert particles together and to remainder of the structure. Improved composite structure exhibits enhanced structural integrity, corrosion resistance and, even when employing refractory material such as sand as the particulate material, exhibits measurably improved heat dissipation characteristics. Methods of making composite structures including a particulate interstitial mass and dynamoelectric machines including such structures.

United States Patent 11 1 1111 3,874,073 Dochterman et a1. Apr. 1, 1975 [54] METHOD OF MANUFACTURING 3,436,569 4/1969 Flahcrty, Jr. ct a1, 310/43 DYNAMOELECTRIC MACHINES 3,493,531 2/1970 Hofmann ct al 264/272 X 3,685,926 8/1972 Blum Inventors: Richard Dochterman, Fort 1124.909 12/1960 Dochterman 310/43 x Wayne, 1nd.; Michael E. Wendt, Tyler, Tex.

Prinuu'i' Examiner-Carl E. Hall [73] Asslgnee' gig 5: i g Company Fort Attorney, Agent, or Firn1.1ohn M. Stoudt; Ralph E.

Krisher, Jr. [22] Filed: July 11,1973 [21] App]. No.: 378,191 [57] ABSTRACT Related Application Data Congposite structurje iniclpdes windjinghsupport with 60 Division of Ser. No. 215,751,111 6, 1972, Pat. No. Wm mgs ate t Ousmg means 1 3,758,799, which is a continuation-in-part of Ser. No. that (1065 not Include a,metal.c.ase 9 and that 6666111129 1970 abandoned does 1nclude a substantially r1g1d primary structural member formed of an interstitial mass of inert particu- [52] US- Cl 29/598, 174/526, 264/272 late material. Resinous material occupies interstices of 310/43 interstitial mass and bonds inert particles together and 1511 1m. c1. l-l02k 15/02 remainder of the Structure Improved COmPOSte [58] Field of Search 29/596, 598', slructur? exhibits enhanced Structural iniegrityt com) 310/4243, 87, 89; 264/272; 174/526 sion res1stance and, even when employmg refractory material such as sand as the particulate material, ex- [56] References Cited 'hibits measurably improved heat dissipation character- UNITED STATES PATENTS istics. Methods of making composite structures mcluding a particulate interstitial mass and dynamoelectric 2.8l4.744 11/1957 Demtriou et a1 .310/43 machines including such structures. 2,948,931) 8/1961) Hcrbst 174/526 3,176,172 3/1965 Thompson ct 111... 310/43 x 8 Clam, 20 Drawmg Flgures 3.433.893 3/1969 Holmann ct a1. 174/153 PATENTEDAPR' 1 I915 SHEET 1 BF 5 PATENTEB 1 5 sum 2 of 5 w. Pl

METHOD OF MANUFACTURING DYNAMOELECTRIC MACHINES CROSS-REFERENCE TO RELATED APPLICATIONS This application is a division of our copending application Ser. No. 215,751 now U.S. Pat. No. 3,758,799, which was filed Jan. 6, 1972 as a continuation-in-part of our then copending application Ser. No. 6,666 filed Jan. 29, 1970, now abandoned. Also related is copending Richard W. Dochterman application Ser. No. 332,508, filed Feb. 14, 1973 as a continuation of then copending application Ser. No. 217,604, filed Jan. 13, 1972, now abandoned, which in turn was a continuation-in-part of then copending application Ser. No. 6,660, filed in the name of Richard W. Dochterman on Jan. 29, 1970 now abandoned. Another related application in copending application Richard W. Dochterman application Ser. No. 211,590, now U.S. Pat. No. 3,745,391, which was filed Dec. 23, 1971 as a division of then copending application Ser. No. 6,664, filed on Jan. 29, 1970, and now U.S. Pat. No. 3,670,405. All of these just mentioned applications and patent are assigned to the assignee of this application and their entire disclosures are incorporated herein by reference.

BACKGROUND OF THE INVENTION This invention relates generally to dynamoelectric machines and composite structures for use therein and,

more particularly, to methods of making dynamoelectric machines including such composite structures and having improved structural integrity and operating characteristics.

It has long been recognized that many diverse and often conflicting criteria must be satisfied by dynamoelectric machines that are reliable and efficient in operation and yet economical to manufacture. For example, motor housing means usually are formed of or at least include an exterior peripheral cover or structure normally referred to as a motor frame, case, or shell. The housing means selected must have sufficient structural integrity to protect the windings supported on a stator core from being damaged during manufacture, handling, or use of the completed machine.

In order to avoid confusion, the term stationary composite structure will be used herein as inclusive of a winding support (e.g., a stator core), one or more windings supported on the winding support, and means (e.g., a frame, case, or shell) used to physically surround and protect the windings and/or winding support. Accordingly, a stationary composite structure or housing means not having an exterior peripheral cover or structure would not include a frame, case, or shell.

Desirably, a stationary composite structure surrounding a rotor (which is also a composite structure) will provide a sound insulating effect, i.e., suppress noise generated during oepration of the machine. In addition, the stationary composite structure must reliably support a bearing system so that an unobstructed and predetermined air gap will be maintained between a selected surface of the stationary composite structure and a selected surface of the composite structure or rotor that is movable relative thereto during operation.

Dynamoelectric machines are often subjected to repetitive stresses such as those caused, e.g., by thermal cycling or by torque pulsation forces which are inherent in the operation of alternating current induction motors. and it is desirable that the stationary composite structure be able to successfully withstand such strains. It is also desirable that means be provided to positively and reliably protect the windings and winding termination connections from damage caused by mechanical shocks, high humidity or other environmental conditions, or corrosive agents that may be encountered during operation.

Notwithstanding the foregoing desiderata, it is particularly desirable that the rapid and efficient dissipation of heat from the windings, bearing system, and rotor be promoted by at least the housing means portion of the stationary composite structure. Furthermore, the material and procedures utilized to manufacture and assemble dynamoelectric machines must be economical and consistently repeatable in order to provide a product of a consistently uniform and high quality. Desirably, such procedures involve a minimum number of steps in practice.

Many years of development and experience have resulted in a determination that there are relatively few different approaches that will yield reasonably satisfactory solutions to the above and other problems. Variations of one general type of approach are illustrated, for example, in Lindt U.S. Pat. No. 3,304,448 and Kaiser U.S. Pat. No. 3,313,968, both of which are assigned to the assignee of the present invention. These patents show that formed or cast metal parts may be used to form a case, frame, or cover around one or more windings supported on a stator core.

Other approaches that have been suggested are described, for example, in the commonly assigned Avila, et al., U.S. Pat. No. 3,002,261 and Thompson, et a1. U.S. Pat. No. 3,165,816. Included in these patents are descriptions of magnetic stator cores and stator windings surrounded by synthetic molding materials. These approaches, however, have not been generally adopted in practice because of the expense of such molding materials as compared to formed or cast metals; because of relatively large amounts of shrinkage that occur during manufacture processes involving many available molding materials; and because such materials are, by comparison with metals, effective thermal insulators and relatively less effective for dissipating the heat generated by a dynamoelectric machine. For these and other reasons the general approach, in practice, has been to use formed or cast metal parts to form external peripheral frames, cases, or shells, which are manufactured to specified dimensional tolerances in order to be satisfactorily assembled with specific stator cores and which are surprisingly susceptible to damage from physical mishandling.

SUMMARY OF THE INVENTION Consequently, it is a primary object of the present invention to provide methods of making improved dynamoelectric machines which solve the problems and overcome the difficulties mentioned above.

Another object of the present invention is to provide a method of making an improved dynamoelectric machine that permits the utilization of low cost commonly available materials.

A further object of the present invention is to provide methods of making improved dynamoelectric machine structures wherein critical dimensional tolerances of various members of such structures (e.g., external peripheral covers) are substantially eliminated by the elimination of such members.

In carrying out the objects of this invention in one form, we provide methods of making dynamoelectric machines having a stationary composite structure that includes a stator assembly comprising a winding sup port formed by stacked Iaminations having a bore and a plurality of winding accommodating slots therein, and a plurality of windings accommodated in the slots of the winding support. The stationary composite struc ture further includes housing means in the form of a substantially solid mass of particulate material and the housing means does not include an exterior peripheral cover. The solid mass of particulate material is illustrated herein, for purposes of explanation, as a mass of common sand particles secured by athermo-responsive resinous material to each other and to the stator assembly. The sand particles are packed against the windings, winding support, and each other and form a substantially rigid interstitial mass withthe resinous or adhesive material occupying the interstices of the interstitial mass. The mass is tightly knit, i.e., loose sand particles are not readily dislodged from the mass. Stationary compositestructures that are made when carrying out our invention eliminate the need for several critical di mensional tolerances required to be maintained heretofore between housings and stator assemblies, and exhibit structural integrity that surpasses conventional arrangements using formed steel and cast iron housing parts as well as good corrosion resistance. These and other characteristics are improved while maintaining, and in some cases improving, noise suppression characteristics as compared to the noise suppression characteristics of conventional steel and cast iron structures.

In spite of the fact that steel and cast iron are far superior conductors of thermal energy as compared to refractory materials in general, the sand in particular, the heat dissipation from actual structures made by the practice of our invention is measurably better when compared with more conventional structures incorporating steel and cast iron parts.

While practicing our invention, the ends of windings and winding termination means connected thereto may be surrounded and rigidly supported by the interstitial particulate mass. With this approach, the termination connection to the windings is practically indestructable. In another form of the invention, we secure at least one bearing support to a composite structure of the dynamoelectric machine with a substantially nonshrinking heat-hardenable adhesive material. This permits a desirable substantially stress-free securement of the bearing support to the composite structure.

In more specific forms of the present invention, we provide an improved method of manufacturing a dynamoelectric machine. In one exemplification, a winding support having windings thereon is positioned in a mold, and an interstitial mass of particulate material with an adhesive bonding material substantially filling the interstices thereof is formed around the winding support and windings. Thereafter, the adhesive bonding material is solidified and the composite structure is removed from the mold.

In still another exemplification, a rotor is positioned in a predetermined position in the bore of a stationary composite structure that includes a solidified intersti-' tial mass of particulate material and bonding material. A bearing system is loosely assembled in an unstressed condition with the rotor and stationary composite structure with a substantially non-shrinking heathardenable structural adhesive material in a plastic state disposed between contiguous portions of the interstitial mass and a bearing support portion of the bearing system. Thereafter, the adhesive material is solidified to secure the bearing support and composite stationary structure with respect to each other.

The subject matter which we regard as our invention is set forth in the appended claimsThe invention itself, however, together with further objects and advantages thereof may be better understood by referring to the following more detailed description taken in conjunc tion with the drawings.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a rear elevation of. a dynamoelectric machine that maybe made by practicing the invention in one form;

FIG. 2 is a view of FIG. 1 taken along the line 2--2 of FIG. 1, with parts in sectionjand parts broken away;

FIG. 3 is a greatly enlarged representation of a photomicrograph of thesurface of the stationary composite structure of the dynamoelectric machine of FIG. 1;

FIGS. 4, 5, 6 and 7 schematically represent the steps of a method exemplifying one form of our invention and which may be utilized to manufacture the dynamoelectric machine of FIG. 1;

FIG. 8 is a perspective view ofa stationary composite structure manufactured according to the method graphically represented in FIGS. 4 through 7;

FIG. 9 is a graphical representation of another method exemplifying the invention;

FIG. 10 is a rear view of another structure made by practicing the invention;

FIG. 11 is a sectional view taken along the line 11-11 of FIG. 10;

FIG. 12 is a front view, with parts broken away, of'the embodiment of FIG. 10;

FIG. 13 is a view taken along the line 13-13 ofFlG. l2;

FIG. 14 is a rear view of still another structure made by practicing the invention;

FIG. 15 is a view, partly in section and partly in full, taken along the line l5l5 of FIG. 14;

FIG. 16 is a view, with parts broken away, similar to FIG. 8, but showing a modified composite structure;

FIG. 17 is a fragmentary view corresponding to a fragment of FIG. 1 and showing an arrangement utilizing the structure of FIG. 16;

FIG. 18 is a fragmentary view corresponding to a fragment of that portion of FIG. 2 that would show, in side elevation, the structure revealed by FIG. 17;

FIG. 19 is a perspective view of a roll pin of the type that is also shown in FIGS. 17 and 18; and

FIG. 20 is a view of another type of roll pin that may be utilized in place of the roll pin shown in FIG. 18.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings in more detail, a dynamoelectric machine is illustrated in FIGS. 1 and 2, as a unit-bearing type motor 20 that includes a stationary composite structure 22 and a bearing system 23 that comprises a bearing support 24 secured to the stationary composite structure, a sleeve bearing 26 pressed into or otherwise secured to the bearing support, lubricating means including a feed wick 27, and an oil cover 28. The motor also includes a rotatable assembly comprising a rotor 29 and shaft 30. The rotor is built of laminated magnetic material and provided with a squirrel cage type secondary winding of conventional design. The rotor 29 is of conventional type and may be substantially similar to the rotor described in the aforementioned Lindt patent. Secured to the bearing support, by means such as spot welds, are mounting means illustrated as threaded studs 31, 32, and 33 which may be used for securing the motor to an appropriate support during operation.

The lubricating means includes conventional material (such as wool felt) disposed in a reservoir defined by the cover 28. This means supplies a lubricant (e.g., motor oil) to the shaft and bearing structure of the motor through a felt feed wick 27.

The cover 28 is secured to the bearing support plate by a novel interlocking arrangement between apertures 34 on the bearing support 24 and expanded fasteners 36 formed in the cover. This arrangement and particular sleeve bearing arrangements and lubrication systems therefor are more fully disclosed and claimed in the previously identified US. Pat. No. 3,670,405.

The stationary composite structure includes a stator assembly that is illustrated as including windings and a winding support in the form of a stator core 37 made of a plurality of stacked laminations. The stator core is of the shaded pole type, having an annular yoke section and angularly spaced apart integral teeth or salient polar projections 38 arranged inwardly of the yoke section, defining respectively enlarged winding accommodating slots between adjacent poles. The tip portions of the poles terminate in arcuate surfaces and form a rotor receiving bore 39. The winding slots extend entirely through the stacks of laminations and accommodate the sides of windings in the form of coils 41 wound around the neck portions of the salient projections. The coils may be wound from a continuous length of suitably insulated wire, with the coils forming a four pole excitation winding having a predetermined number of turns arranged around each polar projection and the free ends thereof connected to the termination means 42. Elongated winding pins of molded plastic or other material extend through the core and axially be yond each polar projection adjacent the bore, and serve to retain the end turns of the individual coils away from the bore.

The termination means 42 are firmly and securely embedded in the stationary composite structure 22. More specifically, conductive terminal elements 43, 44 are secured .at a generally planar insulating terminal support member 46 fabricated from a sheet of electrical insulating material such as fiberboard or other suiti able material; e.g., thermosetting plastic material or mica. The terminal elements each have a portion thereof attached to the support member by suitable means such as an extruded rivet or the like and portions which extend outwardly beyond the stationary composite structure. Thus, the terminal elements form quickconnect terminals exposed for connection to a source of power.

Since the termination means are firmly secured in the stationary composite structure, it is difficult, if not impossible, to dislodge the terminals 43, 44 from the structure 22. Even more importantly, it is virtually im possible to break the electrical connection between the windings and terminals. It will be understood. therefore, that the illustrated arrangement offers a significant advantage over conventional designs. In fact, a review of field rejects of one conventional type of motor has shown that about fifty percent of such field rejects result from terminal failures. That is, the terminals have become loose or electrical continuitybetween the terminals and windings has been broken.

As will be understood, noise is generated during operation of a motor due to the mechanical movement of the rotor in the bore. In addition, the windings and stacked laminations in motors of conventional design have a tendency to vibrate and buzz as a result of the excitation current in the windings. Furthermore, during operation, heat is generated within the stationary composite structure and bearing system of a motor. Use of our invention contributes to the solution of both of these problems and motors made by following the invention may be operated with improved heat dissipation characteristics without degradation of noise suppression characteristics.

The stationary composite structure 22 includes housing means in the form of an interstitial'mass of inert particulate material packed around the winding support, windings, and termination means. A resinous material is disposed in the interstices of the mass and bonds the inert particles into a substantially rigid mass so that the interstitial mass is a self-supporting primary structural member or element of the stationary composite structure 22. The resinous material also bonds the substantially solid mass to the winding support, windings, and termination means. This means is tightly knit, i.e., sand parts are not readily dislodged from the mass.

A wide range of inert particulate materials may be used in the practice of the invention. Desirably, the material selected should withstand the temperatures encountered during manufacturing operations and not deleteriously affect the winding support, windings, terminations, or insulation used on the windings or winding support. In addition, the inert material should not be electrically conductive or magnetic. In general, these same criteria also govern the selection of the particular adhesive material used as a binder for the particulate material. One type of low cost particulate material commonly available in bulk form that is particularly suitable for use is granular refractory material Examples of this type of material are mineral ores, various kinds of rocky material, and sand.

FIG. 3 illustrates the physical structure of the preferred arrangement wherein particles of common sand are packed against each other in random fashion. FIG. 3 is drawn from a photomicrograph of the surface of the housing means portion of the stationary composite structure 22 illustrated in FIG. 1, and the thermoresponsive resinous material disposed in the interstices of the sand mass was essentially transparent. Again, it will be appreciated that the structure is tightly knit.

However, it will be understood that as shown in FIG. 3, the interstices between adjacent particles of sand, e.g., particles 47, 48, 49, 50, are occupied by resinous bonding material that adheres to the sand particles as well as to the stator core 37 and winding coils 41 shown in FIG. 2. The presence of small particles 51 in the structure was also observed, and these were believed to probably be extremely fine particles of sand or impurities in the sand mass.

Since the photomicrograph, of which FIG. 3 is a full scale representation. showed a 70 power enlargement of the interstitial mass, it will be appreciated that the physical interrelationships of particles such as particles 47, 48, 49, 50 are not readily apparent to the naked eye. However. the particles are packed together as illustrated with the resinous binder filling the interstices of the structure.

In general, the sand or other particulate material employed may have a wide range of particle sizes and par ticle size distribution. However, it is desirable to use particulate material wherein about 50 percent by weight of the particles have a size of from 40 to 100 mesh, and it is preferred that such material have an American Foundrymens Society (A.F.S.) fineness of from 45 to 55, since the surface textures of structures wherein the particulate material has a grain fineness in this range is difficult to distinguish from the surface texture of permanent mold cast iron structures.

The meaning of A.F.S. grain fineness number is known in the art and is also set forth in published literature. For example, a description of A.F.S. numbers is contained in the seventh edition (1963) ofa book titled Foundry Sand Handbook and published by the American Foundrymens Society of Des Plaines, Ill.

The calculation of A.F.S. grain fineness numbers is also set forth in this book. A sample calculation therein shows that a sieve analysis is first made of a sample for which the grain fineness number is to be calculated, using US. sieve sizes 6 through 270 and a pan for collecting fines. The weight of the portion of the sample retained on each sieve is then tabulated on an actual weight basis and also as a percentage by weight of the total sample weight. The percents so tabulated are then multiplied by a standard multiplier for each sieve size, and the product ofsuch multiplication is tabulated. The sum of the recorded percentages by weight retained on the sieves and pan is then divided into the sum of the tabulated multiplication products and the result of such division is the A.F.S. grain fineness number. The multipliers for U.S. sieve numbers 6-270 and pan is tabulated in Table I below.

TABLE I U. S. Series Sieve Number Multiplier 2O 10 30 2O 40 30 5O 40 70 50 I00 70 I40 I00 200 140 270 200 Pan 300 sand used. Accordingly. the sand was dried at 400F in a conventional Ferris wheel forced air dryer. After this treatment, the moisture content of the sand was about 0.03% by weight and the dust level was about 0.3% by weight. Thereater, the sand particles retained on a 30 mesh screen were discarded and the remainder used in the exemplification. A sieve analysis of a sample of the sand particles used in the exemplification is set out in Table II below which is presented for purposes of illustration. Standard procedures were followed in making the sieve analysis and, since 30 mesh size particles and larger were discarded prior to the analysis, 100% of the samples tested passed through a 30 mesh screen. The data for two samples is presented in Table II and the last two columns in Table 11 represent an average value of the recorded data for the two samples.

TABLE II of Cumulative Sample 7: passing Retained through Average Sam Sam- Sam- Sam- Sample Cumulative Screen ple ple ple ple retained passing Mesh Size A B A B 7( 3O 0 0 I00 I00 0 40 l6 I8 84 82 I7 83 50 26 24 58 i 58 25 58 70 32 34 26 24 33 25 100 20 20 6 4 2O 5 pan 6 4 5 Although sand was used in the illustrated embodiment of the invention, it will be understood that other inert particulate materials may also be used although with probably not the same economy. No reasons are known by us as to why material such as slate; chalk; zirconia; alumina; calcium carbonate; mica; beryllium oxide; magnesium oxide; or combinations of such materials; or naturally occurring combinations of minerals, e.g., ores, could not be used. For example, we have used chromite ore in lieu of sand to produce structures black in color and having surface textures very similar to castings of permanent mold cast iron. The structural characteristics of these structures were comparable to the corresponding characteristics of the structure of 1 FIG. 1.

For purposes of economy, sand having the previously noted size distribution was used in the FIG. 1 structure, but we have found that satisfactory results are also obtained when the particulate material particles are of substantially uniform size. The primary criteria for our selection, in addition to economic factors, is the structure integrity and final appearance of the composite structures. We believe that if only particles larger than 30 mesh are used, the surface texture of the structure normally will be objectionably course and rough unless excessive amounts of adhesive materials are used to both bind the particles into a substantially solid mass and to smooth out the valleys between adjacent particles adjacent the surface of the mass. This in turn is economical and results in what we term as an objectionable resin-rich surface which will be described more thoroughly hereinafter in the discussion of adhesive materials.

Based on test samples, we also believe that when all of the particulate material is substantially finer than 100 mesh, there will be an objectionable loss of structural integrity of the final structure. A readily apparent manifestation of this loss is the occurrence of fissures and surface crazes in the structures after the resinous material has hardened. It should be added, however, that structures having apparently satisfactory structural integrity (including surface texture) were obtained and substantially all of the particles of particulate material were 100 mesh size. Therefore, we believe that when a substantial percentage or all of the particulate material is finer than 100 mesh, additional means should be used to prevent the development of fissures and crazes in the final structure. By way of illustration, one material which is suitable for use as this additional means in a sand and resin structure is glass fiber such as that discussed in Rudoff, et al. US. Pat. No. 2,820,914.

Many materials are suitable for use as a material for securing or adhesively bonding the particles of the interstitial mass together and to the winding support and windings. We have found it to be quite desirable that the material, regardless of its exact composition, have the following attributes; that it economically secure together the inert particles into a substantially solid mass; that it secure the particles to the remainder of the composite structure; that it be compatible with and not ad vcrsely affect other component parts of the composite structure such as the electrical insulation, winding components, core, and the like (that is, it should be inert with respect to such other parts in the structure); and that it satisfactorily withstand temperatures to which it is to be subjected during fabrication, testing, and use of the completed structure. In addition, the viscosity of the adhesive material should preferably be such that it will be readily retained in the interstitial mass so as to form an essentially non-porous rigid structure after the adhesive material has hardened. We have found that two part thermoresponsive adhesive materials of the thermosetting synthetic resinous type provide these attributes.

When a two part thermosetting resinous material is employed, suitable base resins for this material may include phthalic or non-phthalic type polyesters, epoxys (e.g., bisphcnol A, novolac, cycloaliphatic), certain phenolies, polybutadienes, epoxy-acrylics, and epoxypolyester resins.

A typical two part thermosetting resinous material we have found useful in practice includes, in addition to a base resin as mentioned above, a component to increase the flexural strength of the resinous material when cured, a catalyst to shorten the time required to cure or harden the adhesive material, and an agent to facilitate removal of the composite structure from a mold.

One specific resinous material used in an exemplification included 55 parts by weight polyester resin as the base resin mixed together with 45 parts by weight of styrene (used to increase the flexural strength). To 99 parts by weight of this mixture was added l part by weight of a catalytic agent in the form of tertiary-butylperbenzoate and then 99.45 parts by weight of the foregoing 3 part mixture were mixed with 0.55 parts by weight of a mold release agent. A commercially available mold release agent is marketed under the name "Zelec" by the E. l. DuPont de Nemours and Company, Organic Chemicals Department, 7 South Dearborn Street, Chicago, Ill. However, it should be specifically noted that satisfactory structures have been obtained without using any mold release agents both in TEFLON coated molds and in uncoated molds.

One commercially available polyester resin that we have used is a non-phthalic polyester comprising monobasic and poly-basic acids and polyhydric alcohols. and sold as polyester casting compound No. 5 l9-C-l l l by Con Chemco, i401 Severn Street, Baltimore, Md. Another suitable commercially available base resin is marketed under the name Derakane by the Dow Chemical Co. of Midland, Mich. This particular material is described in detail in US. Pat. No. 3,367,992, which discusses 2-hydroxyalkyl acrylate and methacrylate dicarboxylic acid partial esters and oxyalkylated derivatives thereof. This patent issued Feb. 6, i968 and is assigned to the Dow Chemical Co.

The primary structural member of the stationary composite structure 22 was formed using about 71.2% by weight of sand and 28.8% by weight of the resinous material. After the pores in the sand mass were permeated by the resinous material, the resinous material was retained in the pores or interstices of the sand mass and hardened by heating the stationary composite structure at C for 25 minutes. It will, of course, be understood that different temperatures and varying amounts of catalyst may be used to shorten or lengthen the cure time as desired.

The actual percents by weight of particulate material and resinous material may be varied and were determined in the exemplification by comparing the physical characteristics of stationary composite structures that were made in trials during which the proportion of resinous to particulate material was varied. Since the resinous material, particulate material, winding support, and windings are compatible with each other, the more desirable relative proportions of the materials can be determined by physical inspection and structural testing. in general, we believe that the most economical use of materials, better heat dissipation characteristics, and better structural integrity (i.e., crack-free surfaces, uniform relatively smooth surface textures, resistance to crumbling, crushing, shattering, or breaking) result when we employ a maximum amount of particulate material and a minimum amount of resinous material. When this is done, there is no more resinous material then approximately that required to occupy the voids or pores (i.e., the interstices) between adjacent particles of the particulate mass. lf insufficient amounts of resinous material are used, the structure will be porous, and particles may be scraped from the surfaces (thus, the structure will not be tightly knit throughout); and, in extreme cases, the structure will crumble or fragment when dropped.

The importance of preventing the release of even a single piece of particulate material from a surface of such structures in a motor will be appreciated when it is understood that the air gap or clearance in the bore of a motor often is nominally only about 0.0ll of an inch. Thus, the presence of particulate material, and particularly abrasive refractory material such as sand in the air gap during operation of the motor would result in severe damage, if not destruction, of the motor. For example, noise, binding and freeze up of the shaft in the bearing, and locked rotor conditions may result. if too great an amount of resinous material is used, the external surfaces of the composite structure will be resin rich" and be smooth and glassy in appearance. This effect is particularly objectionable when other structural elements (e.g., bearing means) are to be adhesively secured to the composite structure.

The volume of the interstitial mass is determined essentially by the apparent volume occupied by the particulate material. Thus, the density of specific gravity of the interstitial mass permeated with resinous material is greater than the bulk density of the particulate material. For example, the bulk density of the dry sand used in the exemplification was approximately 1.6 grams per cubic centimeter. However, the density of a section of the bonded sand mass in the stationary composite structure 22 after hardening of the resinous material was approximately 1.9 grams per cubic centimeter.

ln bulk form, the sand mass used in the exemplification has an interstitial volume, i.e., porosity or pore volume of about 34%. Since the securing, e.g., resinous material desirably occupies the interstitial volume of the sand mass, a section of the rigid mass after curing of the resinous material would comprise, on a volumetric basis, about 34% of resinous material and about 66% of sand particles.

Some of the advantages of our invention willbe better appreciated by a comparison of the characteristics of motors constructed according to the teachings presented herein with corresponding characteristics of conventional design motors wherein cast iron and drawn steel parts formed housings for the motors. One of these characteristics is the structural integrity of a motor, e.g., the ability of the motor to withstand physjeal abuse without sustaining damage to the structural or electrical components thereof. One example of such abuse is the mishandling of motors during manufacture or shipment which may subject them to severe impact loading conditions.

ln order to evaluate and compare theeffects of impact loading conditions, twenty-five stationary composite structures constructed according to the invention, and twenty-five conventional stators having a cast iron frame pressed onto a winding support, were dropped from a height of 4 feet onto an iron block.

After the eleventh drop, about one half of the conventional stators literally fell apart and the cast iron shells separated from the stator cores. in addition, the windings in all of the conventional structures had become open circuited. The windings in the impact resistant structures constructed in accordance with the invention, on the other hand, did not open after as many as seventy drops. In addition, no structural damagewas observed in these structures other than spot surface bruises, or external surface spalling. Thus, our new and improved structure was impact resistant as well as selfsupporting.

Motors constructed according to the invention also had noise suppression characteristics at least as good as motors of conventional design. In one text, motors were individually suspended by soft elastic straps and tested in an anechoic sound chamber. During thetest of each motor, a microphone was placed 6 inches away from the noisiest part of the each motor while it operated under no-load conditions. Then the sound pressure, in decibels, of the nose emanating from each motor was recorded. In these tests, twenty motors constructed in accordance with the invention were tested and fifteen cast iron frame type conventional motors were tested. Based on data recorded during these tests,

statistical calculations were made which indicated that,

on the average, the recorded noise levels of the conventional motors were both higher and less uniform than in the case of the motors constructed in accordance with the invention.

These same types of motors were then compared to determine their relative heat dissipation characteristics and, in spite of the fact that the particulate material (sand) in the composite stationary structure is a relatively good heat insulator, the temperature rise of the windings in these motors was less than that of the conventional motors for a given power input. More specifically, it was determined that motors corresponding to the motor of FIG. 1 dissipated 0.879 watts per C rise in winding temperature, whereas the conventional type motors dissipated 0.763 wattsper C rise in winding temperature forabout a 30 rise in winding temperature above ambient. This data was obtained by determining the steady state power supplied to the motors in order to maintain a steady statewinding temperature rise of 30C for ambient temperatures of 25C and 40C. In addition to monitoring the winding temperature, thesteady state temperatures of the exterior surfaces of the stationary composite structures were found to be 150C for the FlG.'2 type motors and C for the conventional motors during locked motor tests. Thus, the FIG. 1 type structures were over 15% more efficient in transferring stator core heat than the conventional motors, since, for a given winding temperature rise, over 15% more power could be supplied to them.

It is believed that the improved heat transfer characteristics of our new and improved motors is at least partly due to the intimate and extensive physical contact that exists between the stator assembly and interstitial mass.

It is believed that it will be evident that dimensional tolerances between'machined parts and susceptibility to rust and other forms of corrosion have been reduced or eliminated by our approach. Again, it is noted that utilization of the present invention permits the elimination of traditional shells, frames, and cases.

Now having referenceto. FIGS. 4-8, the steps of one method exemplifying a form of the invention will be more particularly described. The'method involves the" steps of positioning astator assembly comprising a stator core 61 and windings 62 in ,the cavity 63 of a mold 64 which in turn is resiliently-supported by a spring 66 retained in a support 67 and surrounding a locating boss 68 carried by a friam'e'69fsecured to the mold. In order to space the windings from the bottom of the mold cavity, the stator core: is rested against a stop formed by a le'dgefll in ;the rriold Then -a bore plug 72 having a surface configurationcorresponding to the clesired bore of the. composite structure of FIG. 8 is posi-i tioned in the bore of th'e.statoncore' filf. Attached to the" bore plug is a triangularpiate 73 whieh'provides a con-. toured surface on the composite. structure as will be more fully described hereinafterrln those cases where winding pins may project into thefbore, a taper, as indi-" cated for example at 72b on the bore plug may be used to move and hold-the-pins out of the bore. v 7

After the core a'nd'windings 'are positioned in the mold, a-predetcrmined amount, of particulate refractory material, illustrated for purposes of exemplifi-' cation as sand, is metered anddistributed into the. mold around the core and windings.,The metering means in-- chute 77. Asa predetermined amount of sand 78 sufficient to fill the mold cavity is distributed from three filler tubes 7911,7912, 79cand packs around the core 61, the resiliently supported mold 64 is vibrated by vibrators 80a. 80b to reduce the amount of time required to distribute and pack the sand in the spaces between adjacent turns of the windings, and between the windings and core. As will be understood, any suitable commercially available vibrators may be used. The mold is vibrated horizontally as well as vertically as shown, and the vertical vibrators 80b vibrate the mold through channel shaped plates 81a, 81!) secured to the mold. The vibrations also cause a thin layer of sand to move between the ledge 71 and stator core. This results in the stator core being substantially completely surrounded by an interstitial sand mass.

After being filled with sand, the mold is transferred to a filling station as illustrated in FIG. 6. Then, a cover plate 82 provided with an air admission port 83 and resinous material admission port 84 is secured to the mold by suitable clamping means which may be a plurality of screw fasteners 86 as shown in the drawing. Thereafter, a preselected amount of resinous material is metered through a filler tube 87 from a reservoir 88 into the mold. The material 89 flows across the surface of the sand and effectively forms a pool and air seal across the top of the mold cavity.

Although the material 89 may be permitted to flow by gravity to permeate the mass in the mold, it is more desirable to accelerate the flow of the material 89 through the mass of sand 78 by increasing the pressure differential across the sand mass. Accordingly, after a pool of material 89 is formed in the mold, air with a pressure of 4-6 psig is admitted to the mold through a pressure regulator 91. This pressure forces the material 89 into the interstices of the sand mass, and the sand and material 89 are packed into the mold by the air pressure. The air initially in the interstices of the sand is vented through outlet means in the form of a gap 92 between the end 72a of the bore plug 72 and the mold. The peripheral gap 92 provided for this purpose preferably is sufficiently small to prevent sand or excessive amounts of material 89 from flowing out of the mold while a pressure differential of from 46 psig is maintained across the mold inlet and outlet. When sand and material 89 as described above in the preferred embodiment of FIG. 1 are used in this process, the peripheral gap is about 0.0025 of an inch.

Although it is preferable to form a pressure differential across the mold by the application of a positive pressure to the inlet side of the mold, it will be appreciated that such differential could also be formed by applying a negative pressure or vacuum to the outlet of the mold.

After the material 89 has permeated the mass within the mold cavity, excess resinous material on the top of the mold is removed, e.g., with a squeegee. The resinous material then is cured, i.e., solidified or hardened, so that a tightly knit (i.e., closely and firmly fastened together structure) self-supporting, substantially rigid, impact resistant composite structure capable of effective heat dissipation such as the structure 93 is formed. In this structure, the sand particles are held closely adjacent to one another in a resinous matrix.

When preparing to cure the material 89, the cover 82 is removed and the mold 64 is moved into an oven 94 as shown schematically in FIG. 7 where the mold and composite structure is heated at lC for 25 minutes. At the end of this time, the composite structure is removed from the mold as a rigid, substantially solid mass having the configuration shown in FIG. 8. It will be appreciated that the parameters of time and temperature in the oven may be varied and that the temperature of 190C and time of 25 minutes are given for exemplary purposes only.

The recessed area 95 on the structure 93 is formed by the triangular plate 73. It will be understood that this plate may have any desired configuration that would correspond with the configuration of a bearing support to be positioned thereagainst.

After a composite structure has been formed, assembly of a complete motor may be accomplished. This method will be best understood by again referring to FIGS. 1 and 2. In these figures, after the stationary composite structure 22 has been formed with the interstitial mass forming a housing means without an additional metal or metallic peripheral covering or casing, the rotor 29 is secured in assembled relation with the bearing system by lock washers 96, 97. An epoxy material 98 or other adhesive material as described, for example, in the previously mentioned Thompson, et al., patent is applied to either the bearing support plate 24 or relieved stator assembly housing surface 99 underlying the support plate 24. The bearing plate is then positioned against the surface 99 while the rotor 29 is centrally positioned in the bore 39 by removable shims. After the epoxy 98 is cured, the shims are removed through the openings 34 in the bearing support plate 24. These openings are spaced around and axially aligned with the air gap around the rotor for this purpose. Then the lubrication system is assembled and covered by the cover 28 that in turn is secured to the plate 24 by means of the expanding fasteners 36 previously referred to.

After being assembled, the exterior surfaces of the motor may be prepared for painting by cleaning and etching or priming them. Thereafter, paint may be applied to the motor and dried. These steps may, however, be completely omitted if desired, since it is not necessary to apply a protective coating to the interstitial mass forming the housing for the motor 20, since this structure is resistant to corrosive agents and essentially unaffected by water. In addition, the refractory material and/or resinous material may be used to give a desired final color to the motor 20. For example, chromite ore (as previously described) will provide a structure black in color. On the other hand, white sand will provide a nearly white color, and brown river bed sands provide a buff or beige color. Desired colors may also be obtained by adding a dye or color pigment to the resinous material which then becomes the color determining component in the structure.

Another method is schematically represented by FIG. 9 wherein there is illustrated a mold 121 that comprises two mold parts 122, 123 held together by a mold clamp 124 and supported on a shaft 126 of a motor 127. The mold 121 is removable secured to the shaft by a screw 128 so that it can be rotated by the motor 127. lnitially, the stator core 129 with windings 131 and termination means 132 secured thereto is positioned in the lower mold part 123. Then the upper mold part 122 is positioned against the lower mold part 123 with the termination means 132 projecting through an opening 133 formed in the upper mold part. Thereafter, the

mold clamp 124 is fastened in place to secure the mold parts together.

The motor 127 is cncrgiyed and, as the mold 121 is rotated at a desired speed, a retractable particulate material filler nozzle 134 is moved downwardly to the position illustrated in FIG. 9 so that a predetermined amount of particulate material may be discharged into the mold. In addition, a resinous material dispensing tube 136 (also retractable) is positioned as shown in FIG. 9 to discharge the adhesive material into the cavity of mold 121. The speed of rotation of the mold may be varied, depending on the specific particulate material and particular matrix former, e.g., resinous material, being used.

When using the materials previously described for the cxemplification of FIG. 1, good results are obtained when the mold is rotated at a speed of 1,600 rpm. As the sand I38 and resinous material 137 are concurrently or substantially simultaneously discharged into the rotating mold, heat is applied to the mold and transferred to the structure therewithin by means of a blower 139 which directs hot air across the mold. The centrifugal forces exerted on the sand and resinous material because of the mold rotation pack the sand and resinous material against the walls of the mold, the stator core, windings, and termination means. After predetermined amounts of sand and resinous material have been admitted to the mold, the filler tubes 134 and 136 are withdrawn from the mold, the resinous material is retained in the interstices of the sand mass, and rotation of the mold is continued until the resinous material has cured an amount sufficient to permit removal of a rigid structure from the mold. The final configuration of the composite structure removed from the mold is substantially the same as that of the structure 93 illustrated in FIG. 8.

Although FIG. 9 illustrates the sand 138 and material 137 being concurrently discharged into the mold, it is also possible to discharge the sand into the mold and subsequently add the resinous material. In either case, during the cure cycle of the adhesive material, the rotational speed of the mold may be reduced to about 600 rpm after the sand and resinous material are in place without adversely affecting the structure within the mold.

FIGS. 1l13 depict still another embodiment of the invention wherein a motor 140 comprises a stationary composite structure 141 that includes a stator core 142, windings 143, terminations 144, 146, and housing means formed of an interstitial mass of particulate material. A rotor 147 of conventional construction is secured to a shaft 148 which in turn is supported for rotation by a pair of bearings 149, 151. In order to absorb end thrust during operation of the motor thrust rings, 152, 153 are also carried by the shaft 148 and co-act with the bearings. A bearing lubricant such as oil is stored in reservoirs illustrated as felt wicks 154, 156 which are retained within chambers 157, 158 formed by oil covers 159, 161, bearing supports 162, 163, and internal oil covers 164, 166. The covers 164, 166 include filler tubes 167. 168, respectively. In order to prevent loss of lubricant along the shaft 148, oil slingers 169, 171, 171a, are supported on the shaft 148 and operate in well-known fashion.

As will be appreciated from an inspection of FIGS.

- 10 and 12, the bearing supports 162, 163 are plates which are secured by means such as a thermosetting adhesive material, e.g., epoxy, to the exposed ends 172, 173 of the interstitial mass 174 which forms the primary structural member of the motor. This interstitial mass includes a resinous material and particulate material secured to the core and windings, and is preferably made in the manner and with the materials previously described.

As best revealed in FIGS. 12 and 13, the front of the stationary composite structure is contoured so that the bearing support plate 163 is bonded to lands 176 and spaced from regions 177 of the stationary composite structure. With this arrangement, access to the oil chamber 158 through filler tube 168 is readily available and passages are provided for the flow of coolant such as air through the motor. It will be appreciated that this contouring of surfaces is now attainable as a practical alternative without requiring machining operations on the face of the stationary structure.

To further promote the flow of cooling air through the motor and permit the facile removal of shims used to center the rotor 178 in the air gap during assembly, a plurality of angularly spaced apart openings 179, 181 are formed in the support plates 162, 163, respectively in axial alignment with the air gap around the rotor. These openings are sufficiently large to permit the removal of the shims and provide an unobstructed path to the air gap in the same manner as openings 34 in the exemplification of FIG, 1.

The face 172 of the structure 174 is contoured as shown at 182 in FIGS. 10 and 11 so as to provide access to oil filler tube 167. Although threaded studs 183 are secured to the plate 162 to illustrate means for mounting the motor during operation, it will be appreciated that other mounting means could be employed in this as well as the other embodiments described herein.

FIGS. 14 and 15 illustrate still another approach wherein bearing supports 201, 202 are adhesively secured to the end faces 203, 204 respectively of the housing means portion of stationary composite structure 206. The structure 206 comprises an interstitial mass of sand particles bonded together as previously described. Other components in the motor such as the stator core 208, windings 209, oil retainers 211, 212 and oil covers 213, 214 provide known advantages as will be understood.

As best shown in FIG. 15, end face 204 of the structure 206 is relieved at 205 to provide a clearance for the deformed heads 216 of threaded mounting studs 217. These studs may be riveted or welded to the bearing support 202. As in previously described arrangements, openings such as openings 218 shown in FIG. 14 are provided to permit the easy removal of shims that were used to center the rotor 219 in the air gap 221 during assembly of the rotor and stationary composite structure.

Although the bearing means illustrated herein have included a bearing secured to an end frame or bearing support of the exemplified dynamoelectric machines, it will be understood that the end frame itself may be used as a bearing means without a separate bearing element. In addition, it will be appreciated that when the particulate material is granular in form, the granules may be generally uniform in shape or non-uniform and irregular in shape as was the case of the sand particles in the structures specifically described hereinabove.

The significance of the difference between composite structures (e.g., dynamoelectric machines) constructed according to the invention and those known heretofore may be better appreciated by noting that prior to being listed with Underwriters Laboratories Inc. as impedance protected motors intended primarily for use as household refrigerator condenser fan motors; motors exemplifying the invention were required to meet not only the criteria set forth in U. L. No. 73 tests for motor operated appliances (published in 1967 but still other test criteria not required heretofore of other motors intended primarily for the same use.

By way of illustration. composite structures configured as shown in FIGv 8 were formed of inert particulate material in the form of sand having a 40 to I mesh particle size and held together by a polyesterstyrene resinous material that was formulated to correspond to the specific resinous material described hereinabove. These composite structures were then assembled with rotors and bearing systems to form motors of the unit bearing type shown in FIG. 1. These motors will be referred to hereinafter as submitted motors.

Rather than being subjected to the relatively normal Hi Pot test wherein one test probe is touched to one or both motor terminals and another probe is touched to any part of a metal housing or case while the probes are connected across a potential of 1,240 volts; the submitted motors were subjected to a 5,000 volt hi pot test. Moreover, since the submitted motors did not have a metal shell or housing, they were wrapped in conductive metal foil and then placed in conductive shot. One probe was then placed in circuit with the shot while the other probe was touched to the terminals.

Moreover, the submitted motors were subjected to an abnormal burn out test. In this test, the submitted motors first passed a day locked rotor test and then were wrapped in insulating material, e.g., cotton batting, cheese cloth, or polyurethane foam. Then, with the rotor locked, voltage was applied in 5 volt increments and held under the temperature of the motor housing was stable for 30 minutes or until the motor failed due to winding failure. Depending on the insulation material covering used (c.g., cotton, cloth, or foam); the submitted motors failed safely (without igniting the covering) when 120 to I30 volts were applied. In all of these tests, the housing temperature was from about 280C to about 320C at the time of failure.

An impact test is illustrative of still one other test to which the submitted motors were subjected. In this test, a 2 inch diameter steel ball, weighing l.l8 pounds was dropped so that either 5 or I0 foot pounds of energy were applied to the motors. In this test l0 foot pounds were applied to the motors at room temperature and 5 foot pounds were applied when the motors were at minus 35C. The submitted motors also passed these tests and were only slightly dented or chipped.

In at least some situations, it would be desirable to reduce at least some of the extra tests that motors constructed in the practice of the invention would be subjected to. The modified structures shown in FIGS. 16-18 illustrate one way in which the stator core 37 of a motor may be grounded and thus eliminate the need to pass a 5,000 volt hi pot test.

With reference to FIGS. 1620, the composite structure 250 is similar in all respects to the composite structure 93 of FIG. 8 except that a hole 251 is formed therein. e.g., by a removable pin while the structure is being made. This hole is formed in the recessed surface 252 of the structure and extends to the surface of the stator core 37. A hole is also formed in the plate 24 and then, after assembly of the plate 24 (as modified) with the structure 250, a roll pin, such as pin 254 or pin 255 is driven into holes 253 and 251 to establish a ground circuit path from the core 37 to the plate 24. The pins 254 and 255 may be steel or other suitable material, as will be understood, and each are at least slightly compressible during assembly so that good electrical contact will be maintained with plate 24.

In view of the foregoing, it will be manifest that the advantages and features of our invention are numerous. For example, dynamoelectric machines resulting from practice of the invention are characterized by greatly improved structural integrity; heat dissipation characteristics; and corrosion resistance and noise suppression characteristics that are equally as good as those of motors of conventional design. Moreover, traditional housings or coverings formed of metal or otherwise are no longer needed. Furthermore, winding terminations are better protected than heretofore and critical dimensional tolerances in cast iron and/or drawn steel housing parts have been substantially eliminated. It thus should now be clear that new and improved manufacturing techniques have been illustrated for producing composite structures.

In accordance with the Patent Statutes, we have described what at present are considered to be the preferred and alternate embodiments of our invention, but it will be obvious to those skilled in the art that numerous changes and modifications may be made therein without departing from the invention.

What we claim as new and desire to secure by Letters Patent of the United States is:

l. A method of manufacturing a dynamoelectric machine having at least a rotatable member and a stationary composite structure comprising a winding support, at least one winding accommodated by the winding support, and a self-supporting primary structural member forming a housing for protecting at least part of the one winding, said method comprising: forming the selfsupporting primary structural member as a substantially rigid, self-supporting, exterior housing member around at least part of the winding without an exterior peripheral casing therearound by placing at least the part of the one winding in a mold cavity, by packing within the mold cavity from about 65 to about parts by weight of an interstitial mass of particulate material comprising at least about 50% by weight of from 40 to I00 mesh size particles around said part of the one winding and retaining from about 20 to about 35 parts by weight of an unhardened material in the interstices of the mass, and by hardening the unhardened material to form the primary structural member as a substantially rigid housing member around said part of the one winding; removing the housing member and part of the one winding from the mold cavity; and thereafter supporting the rotatable member for rotation relative to the composite structure.

2. The method of claim 1 wherein packing an interstitial mass of particulate material around part of the one winding and retaining an unhardened material in the interstices of the mass includes packing a mass of relatively dry particulate material around said part of the one winding, and thereafter permeating the mass of particulate material with a fluid resinous material.

3. The method of claim 1 wherein packing an interstitial mass of particulate material around part of the one winding and retaining an unhardened material in the interstices of the mass includes substantially simultaneously forcing particulate material and resinous material against at least part of the winding support and said part of the one winding.

4. A method of manufacturing a dynamoelectric machine comprising a rotor; a stationary composite structure having a stator assembly and housing means for at least part of the stator assembly; and at least one bearing system mounting the stator assembly and the rotor for relative rotation, the method comprising; forming, around at least part of the stator assembly, the housing means so as to be self-supportable without a peripheral covering therearound by positioning at least part of the stator assembly in a mold, by positioning an interstitial mass of from about 65 to about 80 parts by weight of particles of particulate material having an A.F.S. grain fineness number greater than 45 and from about 20 to about parts by weight of a resinous material within the interstices of the mass around at least said part of the stator assembly, and by hardening the resinous material to secure the particles of particulate material together and to at least part of the stator assembly to form at least a portion of the housing means, removing the stationary composite structure so formed from the mold; and positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means.

5. The method set forth in claim 4 wherein positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means includes positioning the rotor relative to the stator assembly to establish a predetermined air gap between the rotor and a selected portion of the stator assembly, securing the rotor in substantially fixed relation to the stator assembly in a substantially stress-free condition by depositing an unhardened adhesive material along at least a portion of the interface of said portion of the housing means and the at least one bearing system, and thereafter hardening the adhesive material.

6. The method set forth in claim 4 wherein positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means includes applying an uncured thermo-responsive material to at least one surface at the interface between the bearing system and the housing means, and thereafter hardening the thermo-responsive material.

7. A method of manufacturing a dynamoelectric machine comprising a rotor; a stationary composite structure having a stator assembly and housing means for at least part of the stator assembly; and at least one bearing system mounting the stator assembly and the rotor for relative rotation, the method comprising the steps of: positioning at least part of the stator assembly in a mold; positioning an interstitial mass of from about 65 to about parts by weight of particles of particulate material and from about 20 to about 35 parts by weight of a resinous material within the interstices of the mass around at least said part of the stator assembly; hardening the resinous material to secure the particles of particulate material together and to at least said part of the stator assembly to form an impact resistant substantially rigid mass and thereby establishing a selfsupporting substantially rigid housing member without need for a peripheral metallic covering; removing the resulting stationary composite structure from the mold; and positioning the rotor relative to the stator assembly, securing the at least one bearing system to the housing means, and supporting the rotor relative to the stator assembly with at least the at least one bearing system.

8. The method set forth in claim 7 wherein securing the at least ,one bearing system to the housing means includes applying an uncured thermo-responsive material to at least one surface at the interface between the bearing system and the housing means and thereafter hardening the thermo-responsive material. 

1. A method of manufacturing a dynamoelectric machine having at least a rotatable member and a stationary composite structure comprising a winding support, at least one winding accommodated by the winding support, and a self-supporting primary structural member forming a housing for protecting at least part of the one winding, said method comprising: forming the self-supporting primary structural member as a substantially rigid, selfsupporting, exterior housing member around at least part of the winding without an exterior peripheral casing therearound by placing at least the part of the one winding in a mold cavity, by packing within the mold cavity from about 65 to about 80 parts by weight of an interstitial mass of particulate material comprising at least about 50% by weight of from 40 to 100 mesh size particles around said part of the one winding and retaining from about 20 to about 35 parts by weight of an unhardened material in the interstices of the mass, and by hardening the unhardened material to form the primary structural member as a substantially rigid housing member around said part of the one winding; removing the housing member and part of the one winding from the mold cavity; and thereafter supporting the rotatable member for rotation relative to the composite structure.
 2. The method of claim 1 wherein paCking an interstitial mass of particulate material around part of the one winding and retaining an unhardened material in the interstices of the mass includes packing a mass of relatively dry particulate material around said part of the one winding, and thereafter permeating the mass of particulate material with a fluid resinous material.
 3. The method of claim 1 wherein packing an interstitial mass of particulate material around part of the one winding and retaining an unhardened material in the interstices of the mass includes substantially simultaneously forcing particulate material and resinous material against at least part of the winding support and said part of the one winding.
 4. A method of manufacturing a dynamoelectric machine comprising a rotor; a stationary composite structure having a stator assembly and housing means for at least part of the stator assembly; and at least one bearing system mounting the stator assembly and the rotor for relative rotation, the method comprising: forming, around at least part of the stator assembly, the housing means so as to be self-supportable without a peripheral covering therearound by positioning at least part of the stator assembly in a mold, by positioning an interstitial mass of from about 65 to about 80 parts by weight of particles of particulate material having an A.F.S. grain fineness number greater than 45 and from about 20 to about 35 parts by weight of a resinous material within the interstices of the mass around at least said part of the stator assembly, and by hardening the resinous material to secure the particles of particulate material together and to at least part of the stator assembly to form at least a portion of the housing means, removing the stationary composite structure so formed from the mold; and positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means.
 5. The method set forth in claim 4 wherein positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means includes positioning the rotor relative to the stator assembly to establish a predetermined air gap between the rotor and a selected portion of the stator assembly, securing the rotor in substantially fixed relation to the stator assembly in a substantially stress-free condition by depositing an unhardened adhesive material along at least a portion of the interface of said portion of the housing means and the at least one bearing system, and thereafter hardening the adhesive material.
 6. The method set forth in claim 4 wherein positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means includes applying an uncured thermo-responsive material to at least one surface at the interface between the bearing system and the housing means, and thereafter hardening the thermo-responsive material.
 7. A method of manufacturing a dynamoelectric machine comprising a rotor; a stationary composite structure having a stator assembly and housing means for at least part of the stator assembly; and at least one bearing system mounting the stator assembly and the rotor for relative rotation, the method comprising the steps of: positioning at least part of the stator assembly in a mold; positioning an interstitial mass of from about 65 to about 80 parts by weight of particles of particulate material and from about 20 to about 35 parts by weight of a resinous material within the interstices of the mass around at least said part of the stator assembly; hardening the resinous material to secure the particles of particulate material together and to at least said part of the stator assembly to form an impact resistant substantially rigid mass and thereby establishing a self-supporting substantially rigid housing member without need for a peripheral metallic covering; removing the resulting stationary composite structure fRom the mold; and positioning the rotor relative to the stator assembly, securing the at least one bearing system to the housing means, and supporting the rotor relative to the stator assembly with at least the at least one bearing system.
 8. The method set forth in claim 7 wherein securing the at least one bearing system to the housing means includes applying an uncured thermo-responsive material to at least one surface at the interface between the bearing system and the housing means and thereafter hardening the thermo-responsive material. 